Golf club head with a carbon fiber block

ABSTRACT

A golf club head has a body and a carbon filter block. The body has a face defined on one side of the body. A tubular neck is integrally formed on one end of the body. A cavity is defined in the body opposite to the face. The carbon fiber block is mounted in the cavity. Because the carbon fiber material is lighter than metal, the area of the face is enlarged. In addition, a better shock absorbing effect is achieved due to the arrangement of the carbon fiber block.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to a golf club head, and more particularly to a golf club head with a carbon fiber block, such that the face of the golf club head can be enlarged.

[0003] 2. Description of Related Art

[0004] With reference to FIG. 4, a conventional golf club head (40) for an iron comprises a body (41) and a tubular neck (43). A face (42) is defined in one side of the body (41) for hitting the golf ball. The neck (43) is integrally formed on one end of the body (41) to connect with a shaft of a golf club. In general, the golf club head (40) is usually manufactured in one of two ways, one is to cast the head (40) with a mold, and the other is forge the head from a single block of metal. However, because the conventional iron head (40) is always made of metal and the weight of the golf club head is standardized, the area of the face (42) of the golf club head (40) is limited. A new golfer easily misses the golf ball with an iron having a conventional head (40).

[0005] To overcome the shortcomings, the present invention tends to provide an improved golf club head to mitigate or obviate the aforementioned problems.

SUMMARY OF THE INVENTION

[0006] The main objective of the invention is to provide an improved iron head having a face with a large area. The iron head in accordance with the present invention has a body and a carbon fiber block. The body has a face defined on one side of the body. A tubular neck is integrally formed on one end of the body. A cavity is defined in the body opposite to the face. The carbon fiber block is mounted in the cavity. Because the carbon-fiber material is lighter than the metal, the area of the face is enlarged. In addition, a better shock absorbing effect is achieved due to the carbon-fiber cover.

[0007] Other objects, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008]FIG. 1 is an exploded perspective view of a golf club head for an iron in accordance with the present invention;

[0009]FIG. 2 is a cross sectional side plan view of the golf club head in FIG. 1;

[0010]FIG. 3 is a block diagram of a method for manufacturing the golf club head in FIG. 1; and

[0011]FIG. 4 is a perspective view of a conventional iron golf club head in accordance with the prior art.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

[0012] With reference to FIG. 1, a golf club head in accordance with the present invention comprises a body (10) and a carbon fiber block (20). The body (10) has a face (11) defined on one side of the body (10) for hitting the golf ball. A tubular neck (12) is integrally formed on one end of the body (10) to connect with a shaft of an iron. A cavity (13) is defined in the body (10) opposite to the face (11).

[0013] The carbon fiber block (20) is securely mounted in the cavity (13). A lip (132) laterally extends from the face defining the cavity (13) of the body (10) to engage the block (20), such that the attachment between the body (10) and the block (20) is enhanced.

[0014] At least one countersunk through hole (21) is defined in the block (20). A weighted plug (30) is-inlaid in each-countersunk through hole (21) in the block (20). Each weighted plug (30) has a head (31) and a shaft (32). The plug (30) shaft (32) integrally extends from the head (31). The head (31) has a diameter larger than the shaft (32). The head (31) of each weighted plug (30) is received in one of the recesses (22) in the countersunk hole (21). The shaft (32) of each weighted plug (30) extends through and engages with the corresponding countersunk through hole (21). At least one annular groove (322) is defined around the outer periphery of the shaft (32) of each weighted plug (30). A rib is formed in the inner periphery of each through hole (21) to engage with each annular groove (322) in the shaft (32) of the corresponding weighted plug (30). Consequently, each weighted plug (30) is securely held in the block (20). In addition, a blind hole (14) is defined in the face defining the cavity (13) of the body (10) and aligns with each countersunk through hole (21) in the block (20). The free end of the shaft (32) of each weighted plug (30) extends into and is received in the corresponding blind hole (14).

[0015] With reference to FIGS. 1 to 3, the process of manufacturing the golf club head comprises the steps as fellows:

[0016] a. forming the body (10):

[0017] The body (10) with the neck (12) and the cavity (13) is formed with a cast molding process. The blind holes (14) are drilled in the face defined in the cavity (13). The lip (132) is simultaneously formed on the face defining the cavity (13) in the molding process. The body (10) is then ground to a desired shape and size.

[0018] b. spraying aluminum oxide sand onto the inner surface of the cavity (13):

[0019] By spraying aluminum oxide sand onto the inner surface of the cavity (13) of the-body (10) the surface roughness of the inner surface of the cavity (13) is increased.

[0020] c. attaching the block (20) to the body (10):

[0021] The block (20) is formed from multiple carbon fiber layers. The countersunk through holes (21) with recesses (22) are defined in the block (20). The block (20) is then put into the cavity (13) in the body (10).

[0022] d. inserting the weighted plugs (30) into the block (20):

[0023] A weighted plug (30) is inserted into each countersunk through hole (21). The free end of the shaft (32) of each weighted plug (30) is inserted into the corresponding blind hole (14) in the body (10).

[0024] e. hot-pressing mold process:

[0025] The head with the block (20) is put into a mold of a hot-pressing machine. During the hot-pressing mold process, the block (20) will harden and be securely attached to the inner surface of the cavity (13). Simultaneously, the block (20) is attached to the lip (14) in the cavity (13). Because the inner face of the cavity (13) has been sprayed with aluminum oxide sand, the attachment between the block (20) and the body (10) is enhanced. The weighted plugs (30) received in the countersunk through holes (21) will be securely held in the block (20) simultaneously when the block (20) hardens during the hot-pressing mold process. In addition, at least one annular groove (322) is defined in the outer periphery of each second block (22). A rib will be automatically formed in each through hole (21) during the hot-pressing mold process to connect with each annular groove (322) in each weighted plug (30). The attachment between each weighted plug (30) and the block (20) is enhanced. Consequently, the position of the center of gravity of the golf club-head is adjustable based on the position and arrangement of the weighted plugs (30).

[0026] f. fine grinding:

[0027] To increase the smoothness of the surface of the golf club head, a fine grinding process is carried out.

[0028] g. coating: and

[0029] The outer surface of the golf club head is coated with lacquer to provide a protective coating on the head.

[0030] h. packing:

[0031] The golf club head is packed.

[0032] Accordingly, a golf club head with a carbon fiber block (20) is made. Because the weight of the carbon fiber material is lighter than the metal, the weight of the golf club head is reduced. Consequently, a face (11) having a larger area can be formed on the golf club head that is the same weight as the conventional golf club head made of metal. The face (11) is enlarged. The likelihood of completely missing the golfball can be greatly reduced. In addition, because the elasticity of the carbon fiber material is better than that of the metal material, the shock absorbing effect of the golf club head is improved.

[0033] Even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. 

What is claimed is:
 1. A golf club head comprising: a body having a face defined on one side of the body; a tubular neck integrally formed on one end of the body; a cavity defined in the body opposite to the face; and a carbon fiber block mounted in the cavity of the golf club head, thereby the face having a larger area can be formed on the body.
 2. The golf club head as claimed in claim 1 further comprising at least one weighted plug inlaid into the block to change the gravity center of the golf club head.
 3. The golf club head as claimed in claim 2, wherein each at least one weighted plug comprises a head and a shaft extending form the head; a countersunk through hole is defined in the block through which the shaft of the weighted plug extends and connects to the countersunk through hole; and a countersunk recess receives the head of each at least one weighted plug.
 4. The golf club head as claimed in claim 3, wherein a blind hole is defined in a face defining the cavity of the body and aligns with each countersunk through hole in the block to receive a free end of the shaft of the corresponding one of the at least one weighted plug.
 5. The golf club head as claimed in claim 4, wherein at least one annular groove is defined in an outer periphery of the shaft of each at least one weighted plug; and a rib is formed in an inner periphery of each through hole to engage with each at least one annular groove in the shaft of the corresponding one of the at least one weighted plug.
 6. The golf club head as claimed in claim 1, wherein a lip laterally exends from a face defining the cavity in the body to engage with the block. 